RISK-BASED INSPECTION 31

6.6 Estimating Resources and Time Required

The resources and time required to implement an RBI assessment will vary widely between organizations depending
on a number of factors including the following:

a) implementation strategy/plans.

b) knowledge and training of implementers.

c) availability and quality of necessary data and information.

d) availability and cost of resources needed for implementation.

e) amount of equipment included in each level of RBI analysis.

f) degree of complexity of RBI analysis selected.

g) degree of precision required.

The estimate of scope and cost involved in completing an RBI assessment might include the following:

a) number of facilities, units, equipment items, and components to be evaluated;

b) time and resources required to gather data for the items to be evaluated;

c) training time for implementers;

d) time and resources required for RBI assessment of data and information;

e) time and resources to evaluate RBI assessment results and develop inspection, maintenance, and mitigation plans;

f) type of analysis (qualitative, semi-quantitative and/or quantitative) to be conducted.

7 Data and Information Collection for RBI Assessment

7.1 General

Utilizing the objectives, boundaries, level of approach, and resources identified in Section 6, the objective of this
section is to provide an overview of the data that may be necessary to develop an RBI plan.

The data collected will provide the information needed to assess potential damage mechanisms, potential failure
modes, and scenarios of failure that are discussed in Section 8. Additionally, it will provide much of the data used in
Section 9 to assess probabilities, the data used in Section 10 to assess consequences, and data used in Section 12
--`,,`,,,`,,``,,,,```,,`,``,,`,-`-`,,`,,`,`,,`---

to assist in inspection planning.

Examples of data sources include the following:

a) design and construction records;

b) inspection and maintenance records;

c) operating and process technology records;

d) hazards analysis and management of change (MOC) records;

Copyright American Petroleum Institute

Provided by IHS under license with API Licensee=Marathon Petroleum Co. LP/0320300001, User=Ray, Brent
No reproduction or networking permitted without license from IHS Not for Resale, 05/05/2016 16:34:00 MDT
 32 API RECOMMENDED PRACTICE 580

e) Materials selection records, corrosion engineering records, and library/database;

f) Cost and project engineering records.

The precision of the data should be consistent with the RBI method used. The individual or team should understand
the precision of the data needed for the analysis before gathering it. It may be advantageous to combine risk analysis
data gathering with other risk/hazard analysis data gathering (see 5.7) as much of the data may be the same.

7.2 RBI Data Needs

7.2.1 General

An RBI study may use a qualitative, semi-quantitative, and/or quantitative approach (see 5.3). A fundamental
difference among these approaches is the amount and detail of input, calculations, and output.

For each RBI approach it is important to document all bases for the study and assumptions from the onset and to apply
a consistent rationale. Any deviations from prescribed, standard procedures should be documented. Documentation of
unique equipment and piping identifiers is a good starting point for any level of study. The equipment should also
correspond to a unique group or location such as a particular process unit at a particular plant site.

Typical data needed for an RBI analysis may include but is not limited to the following:

a) type of equipment;

b) materials of construction;

c) inspection, repair, and replacement records;

d) process fluid compositions;

e) inventory of fluids;

f) operating conditions;

g) safety systems;

h) detection systems;

i) damage mechanisms, rates, and severity;

j) personnel densities;

k) coating, cladding, and insulation data;

l) business interruption cost;

--`,,`,,,`,,``,,,,```,,`,``,,`,-`-`,,`,,`,`,,`---

m) equipment replacement costs;

n) environmental remediation costs.

7.2.2 Data Needs for Qualitative RBI

A more qualitative approach typically does not require all of the data mentioned in 7.2. Further, items required only
need to be categorized into broad ranges or classified versus a reference point. It is important to establish a set of
rules to assure consistency in categorization or classification.

Copyright American Petroleum Institute

Provided by IHS under license with API Licensee=Marathon Petroleum Co. LP/0320300001, User=Ray, Brent
No reproduction or networking permitted without license from IHS Not for Resale, 05/05/2016 16:34:00 MDT
 RISK-BASED INSPECTION 33

Generally, a qualitative analysis using broad ranges requires a higher level of judgment, skill, and understanding from
the user than a more quantitative approach. Ranges and summary fields may evaluate circumstances with widely
varying conditions requiring the user to carefully consider the impact of input on risk results. Therefore, despite its
simplicity, it is important to have qualified persons perform the qualitative RBI analysis.

7.2.3 Data Needs for Quantitative RBI

Quantitative RBI uses logic models depicting combinations of events that could result in severe accidents and
physical models depicting the progression of accidents and the transport of a hazardous material to the environment.
The models are evaluated probabilistically to provide both qualitative and quantitative insights about the level of risk
and to identify the design, site, or operational characteristics that are the most important to risk. Hence, more detailed
information and data are needed for a fully quantitative RBI in order to provide input for the models.

7.2.4 Data Needs for Semi-quantitative RBI

The semi-quantitative analysis typically requires the same type of data as a quantitative analysis, but generally not as
detailed. For example, the fluid volumes may be estimated. Although the precision of the analysis may be less, the
time required for data gathering and analysis will be less too; however, that does not mean that the analysis will be
less accurate (see 5.4).

7.3 Data Quality

The data quality has a direct relation to the relative accuracy of the RBI analysis. Although the data requirements are
quite different for the various types of RBI analysis, quality of input data is equally important no matter what approach
to RBI is selected. Data inputs and assumptions shall be validated by qualified personnel such as process engineer/
operator to review operating parameters used (see Section 15).

As is true in any inspection program, data validation is essential for a number of reasons. Among the reasons for
inspection data quality errors are the following:

a) outdated drawings and documentation;

b) errors within inspection planning, execution, and documentation;

c) clerical and data transcription errors;

d) measurement equipment accuracy.

Another potential source of scatter and error in the analysis is assumptions on equipment history. For example, if
baseline inspections were not performed or documented, nominal thickness may be used for the original thickness.
This assumption can significantly impact the calculated corrosion rate early in the equipment life. The effect may be to
mask a high corrosion rate or to inflate a low corrosion rate. A similar situation exists when the remaining life of a
piece of equipment with a low corrosion rate requires inspection more frequently. The measurement error may result
in the calculated corrosion rate appearing artificially high or low. It is important that those making assumptions
understand the potential impact of their assumptions on the risk calculation.
--`,,`,,,`,,``,,,,```,,`,``,,`,-`-`,,`,,`,`,,`---

This validation step stresses the need for a qualified person comparing data from the inspections to the expected
damage mechanism and rates. This person may also compare the results with previous measurements on that
system, similar systems at the site, or within the company or published data. Statistics may be useful in this review.
This review should also factor in any changes or upsets in the process. As mentioned previously, this data validation
step is necessary for the quality of any inspection program, not just RBI. Unfortunately, when this data validation step
has not been a priority before RBI, the time required to do it gets included with the time and resources necessary to
do a good job on RBI, leaving the wrong impression with some managers believing that RBI is more time consuming
and expensive than it should be.

Copyright American Petroleum Institute

Provided by IHS under license with API Licensee=Marathon Petroleum Co. LP/0320300001, User=Ray, Brent
No reproduction or networking permitted without license from IHS Not for Resale, 05/05/2016 16:34:00 MDT
 34 API RECOMMENDED PRACTICE 580

7.4 Codes and Standards—National and International

In the data collection stage, an assessment of what codes and standards are currently in use for in-service inspection
and evaluation, or were in use during the equipment design, is generally necessary. The selection and type of codes
and standards used by a facility can have a significant impact on RBI results.

7.5 Sources of Site-specific Data and Information

Information for RBI can be found in many places within a facility. It is important to stress that the precision of the data
should match the complexity of the RBI method used (see 5.4). The risk analysis and RBI team should understand
the sensitivity of the data needed for the program before gathering any data. It may be advantageous to combine RBI
data gathering with other risk/hazard analysis data gathering [e.g. PHA, RCM, quantitative risk assessment (QRA)] as
much of the data overlaps.

Potential sources of specific information include but are not limited to the following.

a) Design and construction records/drawings:

1) P&IDs, process flow diagrams, material selection diagrams (MSDs), etc.;

2) piping isometric drawings;

3) engineering specification sheets;

4) materials of construction records;

5) construction quality assurance/quality control (QA/QC) records;

6) codes and standards used;

7) protective instrument systems;

8) leak detection and monitoring systems;

9) isolation systems;

10) inventory records;

11) emergency depressurizing and relief systems;

12) safety systems;

13) fire-proofing and fire-fighting systems;

14) layout.

b) Inspection records:

1) schedules and frequency;

2) amount and types of inspection;

3) repairs and alterations;

4) positive material identification (PMI) records;

5) inspection results.

--`,,`,,,`,,``,,,,```,,`,``,,`,-`-`,,`,,`,`,,`---

Copyright American Petroleum Institute

Provided by IHS under license with API Licensee=Marathon Petroleum Co. LP/0320300001, User=Ray, Brent
No reproduction or networking permitted without license from IHS Not for Resale, 05/05/2016 16:34:00 MDT
 RISK-BASED INSPECTION 35

c) Process data:

1) fluid composition analysis including contaminants or trace components;

2) distributed control system data;

3) operating procedures;

4) start-up and shutdown procedures;

5) emergency procedures;

6) operating logs and process records;

7) PSM/PSI, PHA, RCM, FMEA, and QRA data or reports.

d) MOC records.

e) Off-site data and information—if consequence may affect off-site areas.

f) Failure data:

1) generic failure frequency data—industry or in-house;

2) industry-specific failure data;

3) plant- and equipment-specific failure data;

4) reliability and condition monitoring records;

5) leak data.

g) Site conditions:

1) climate/weather records;

2) seismic activity records.

h) Equipment replacement costs:

1) project cost reports;

2) industry databases.

i) Hazards data:

1) PSM studies;

2) PHA studies;

3) QRA studies;

4) other site-specific risk or hazard studies.

j) Incident investigations.

--`,,`,,,`,,``,,,,```,,`,``,,`,-`-`,,`,,`,`,,`---

Copyright American Petroleum Institute

Provided by IHS under license with API Licensee=Marathon Petroleum Co. LP/0320300001, User=Ray, Brent
No reproduction or networking permitted without license from IHS Not for Resale, 05/05/2016 16:34:00 MDT